US2637592A - Automobile body structure - Google Patents

Automobile body structure Download PDF

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US2637592A
US2637592A US103519A US10351949A US2637592A US 2637592 A US2637592 A US 2637592A US 103519 A US103519 A US 103519A US 10351949 A US10351949 A US 10351949A US 2637592 A US2637592 A US 2637592A
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passenger
automobile
sections
wheel
beams
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US103519A
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Karlby Henning
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60GVEHICLE SUSPENSION ARRANGEMENTS
    • B60G3/00Resilient suspensions for a single wheel
    • B60G3/02Resilient suspensions for a single wheel with a single pivoted arm
    • B60G3/12Resilient suspensions for a single wheel with a single pivoted arm the arm being essentially parallel to the longitudinal axis of the vehicle
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60GVEHICLE SUSPENSION ARRANGEMENTS
    • B60G3/00Resilient suspensions for a single wheel
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60GVEHICLE SUSPENSION ARRANGEMENTS
    • B60G3/00Resilient suspensions for a single wheel
    • B60G3/18Resilient suspensions for a single wheel with two or more pivoted arms, e.g. parallelogram
    • B60G3/20Resilient suspensions for a single wheel with two or more pivoted arms, e.g. parallelogram all arms being rigid
    • B60G3/24Resilient suspensions for a single wheel with two or more pivoted arms, e.g. parallelogram all arms being rigid a rigid arm being formed by the live axle
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60GVEHICLE SUSPENSION ARRANGEMENTS
    • B60G7/00Pivoted suspension arms; Accessories thereof
    • B60G7/02Attaching arms to sprung part of vehicle
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B62LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62DMOTOR VEHICLES; TRAILERS
    • B62D21/00Understructures, i.e. chassis frame on which a vehicle body may be mounted
    • B62D21/11Understructures, i.e. chassis frame on which a vehicle body may be mounted with resilient means for suspension, e.g. of wheels or engine; sub-frames for mounting engine or suspensions
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B62LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62DMOTOR VEHICLES; TRAILERS
    • B62D23/00Combined superstructure and frame, i.e. monocoque constructions
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B62LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62DMOTOR VEHICLES; TRAILERS
    • B62D31/00Superstructures for passenger vehicles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60GVEHICLE SUSPENSION ARRANGEMENTS
    • B60G2200/00Indexing codes relating to suspension types
    • B60G2200/10Independent suspensions
    • B60G2200/13Independent suspensions with longitudinal arms only
    • B60G2200/132Independent suspensions with longitudinal arms only with a single trailing arm
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60GVEHICLE SUSPENSION ARRANGEMENTS
    • B60G2200/00Indexing codes relating to suspension types
    • B60G2200/10Independent suspensions
    • B60G2200/14Independent suspensions with lateral arms
    • B60G2200/141Independent suspensions with lateral arms with one trailing arm and one lateral arm only
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60GVEHICLE SUSPENSION ARRANGEMENTS
    • B60G2204/00Indexing codes related to suspensions per se or to auxiliary parts
    • B60G2204/10Mounting of suspension elements
    • B60G2204/14Mounting of suspension arms
    • B60G2204/143Mounting of suspension arms on the vehicle body or chassis
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60GVEHICLE SUSPENSION ARRANGEMENTS
    • B60G2206/00Indexing codes related to the manufacturing of suspensions: constructional features, the materials used, procedures or tools
    • B60G2206/01Constructional features of suspension elements, e.g. arms, dampers, springs
    • B60G2206/10Constructional features of arms
    • B60G2206/11Constructional features of arms the arm being a radius or track or torque or steering rod or stabiliser end link

Definitions

  • This invention relates :to passenger automobile :structures of the so-called pleasure near 1 type ,and has i for? its general object to strengthen and lightensuch structuresxandat the same'time to-improve the overall .efiiciency, stability, rideability and durability-of automobiles, while-im- --.proving--their fitness forg quantity. production.
  • This expensive structure houses a power plant located .at the frontlfor driving therear wheels.
  • This rear wheel drive not only is the: cause of much of the directional instability. of an auto. in. operation but also .brings. about .a. weight distribution whichleads to still more instability.
  • wheelsindividually suspended from very soft springs are the onlymeans of assuring efficient ground. adherence and freedom .from
  • An important object of the present invention therefore, --is tov replace the vconglonmeration of gpartsrmakingup the body ,andframe structure 10f the present day automobile by whatisessentially a single member of vastly superior strength, lower weight and greatly reduced assembly cost, and pleasing appearance, while leaving free access to all mechanical components of the automobile.
  • the invention aim to increase the structural strength and reduce the weight and assembly cost of automobile frame and body structures, but it further aims to increase the overall efficiency and the operating stability of automobiles.
  • the unitary structure of the present invention not only replaces the conglomeration of parts making up the frame and body structure of the present day automobile, but is so designed that it will resist both bending and twisting, that it will serve as an effective shield for the occupants, that it will be so light that it will impede acceleration very little, that it will have low air drag, and that any obstruction of vision will be minimized as much as possible.
  • the invention aims to provide a passenger body structure which is essentially and in its own design such a highly efiicient beam-shaft as to serve in itself the functions of the normal frame and is of such high local impact strength as to serve in itself the functions of impact shield and bumpers.
  • beam shaft used herein is meant a hollow structure having external walls adapted to serve like the walls of a box beam to resist bending, but also curved without sharp corners substantially throughout its periphery, so that it acts also as a shaft to resist torsion.
  • the present invention achieves these objects first by utilizing structurally nearly all the material used in the automobile and by making the body and fenders in a unitary beam shaft structure, a closed box beam without sharp corners and enclosing the largest possible cross sectional area.
  • the invention contemplates a vehicle structure in which, after delineating all of the spaces required (1) for operating parts; (2) for access to the operating parts; (3)
  • the invention contemplates a further significant improvement in the combination with this of a very simple and rugged individual wheel mounting and springing.
  • Still another aim of the invention is to take full advantage of such a combined frame and passenger body structure with its superior overall strength and resistance to deformation by a rearrangement of the mechanical elements of the automobile contributing much to its stability and rideability.
  • An important object of the invention is to eliminate the extraneous non-structural parts that were hitherto required as separate parts and also the frames and fastenings which were required for the support and positioning of such essentially non-structural elements.
  • the invention contemplates making a selfframing passenger body structure substantially entirely with the exception of the top and a relatively few fittings, from sheet metal of relatively heavy gauge, 1. e., substantially stronger than has heretofore been used for the body skin and lighter than is ordinarily used for framing automobiles of similar capacity and performance.
  • the number of preformed shells required for assembly into the improved self-framing body structure is reduced to two which can be stamped from heavy sheets on production presses.
  • the passenger space is first determined beginning with the desired comfortable seats for three people on each of two seats and with comfortable spacing for feet and legs. Beyond this passenger space at each end the wheels are arranged and motor and luggage compartments are extended 'therebeyond at the front and rear respectively. With these several spaces for power plant, for passengers, for luggage and for wheels determined, a space between and around them is enclosed by a beam shaft structure having the required road clearance in its lowest parts and having necessary clearance below lines of sight required for driving. [he shape shown is a design of funtional art, but many other designs both decorative and functional can be used, the designer having a wide latitude of choice by virtue of this invention.
  • Figure 1 is a side elevation of the complete automobile having a top attached to the basic body structure
  • Figure 2 is a front elevation showing the arrangement of the air intake, headlights, etc.
  • Figure 3 is an isometric view of the upper of two preformed sheet metal stampings employed in producing the-embodiment of the invention herein illustrated;
  • Figure 4 is an isometric view of the-lower ofthe two shells required to produce the illustrative embodiment
  • Figure 5 is a view in central, longitudinal vertical section, showing the shells of Figures 3 and 4 assembled into the self-framing passenger body structure of the present invention, these. shells being welded together at their meeting edges;
  • Figure 6 is an enlarged view in vertical transverse section taken on line 6-6 of Figure 5, but with the motor shown in front elevation;
  • Figure 7 is a view in vertical section taken on line 7'! of Figure 5;
  • Figure 8 is a transverse vertical section taken on line 8-8 of Figure 5; i
  • FIG. 9 is a transverse section on line 9-9 of Figure 5;
  • Figure 10 is a bottom plan View of a complete automobile embodying the present invention, showing the location of the wheel supports, wheels, gasoline tank, motor, driving connections, etc.;
  • Figure 11 is a longitudinal, vertical section taken through the upper and lower shell assembly
  • Figures 12 through 21 inclusive are diagrammatic sections through the self-framing, body structure respectively on the lines l2--
  • FIGS 22 and 23 are detail views showing how the shells may be secured together by bolts or spot welding;
  • - Figure 24 is a fragmentary sectional view of one front wheel and associated parts, particular the brake mechanism
  • Figure 25 is a fragmentary sectional View taken on line 25-25 of Figure 1;
  • Figure 26 is a cross-section taken on line 26-46 of Figure 25;
  • Figure 27 is a fragmentary phantom plan view of the front end of the automobile.
  • Figure 28 is an exploded view of the parts which make up a self-framing body in another embodiment of the invention.
  • Figure 29 is a fragmentary section through a door sill showing how the parts of Figure 28 are welded together into a box beam structure.
  • the twoshells 2 and 4 combine to.
  • an overall beam-shaft i. e., the two shells when welded or otherwise secured together form a hollow structure having a high stiffness/weight ratio because of its box-beam cross-section.
  • these shells are formed so as to provide box-beams peripherally of the automobile, especially across the front and-along the sides.
  • an engine Well is substantially surrounded by a torodial box beam section and the passenger space is reinforced by transverse box beam sections.
  • the body is in effect a series ofqspaces for engine, passengers and luggage,
  • each surrounded by box beam structures integral a with the other parts of the body.
  • the lower surface of this body is smooth to give relatively little air drag, and to give high impact resistance by lying flat in a horizontal plane, parallel to the direction of destructive impacts.
  • the upper shell 2 is shaped to form the upper and inside faces of two longitudinal box beams 6 and 8, and the connecting integral cross beams 9, I0, and I2 located under the cowl and beneath the passenger seats, respectively, the floor of the passenger compartment being shown at M between the rear and front seats and at I6 between the front seat and the dash l8, which is integral with the overhanging cowl 20 which, in turn, is integral with the toroidal frame portion which serves as hood sides 22 and extends over the front wheels and forms a part of the front wheel fenders.
  • the upper part of the rear cross beam i2 is shaped to support the back cushion for the rear seat and to constitute a part of a stiffening cross beam shape of which the upper wall 23 of the baggage compartment constitutes another part. It will be seen that the box beams 6 and 8 are carried up over the rear wheels to form a part of the integral rear wheel fenders 24, 26.
  • the lower shell 4 as shown in Figure 4, is likewise so designed that it can be pressed from sheet metal upon a stamping press by drawing dies. As shown the shell 4 is shaped to cooperate with the corresponding beam-forming elements of the upper shell 2 to form the structurally strong longitudinal box beams 6 and -8, the cross beams 9, Ill, and I2 etc. It is also shaped to provide recesses 24 and 26 for the .two
  • this section consists of the two box beams 6 and 8 joined by an integral double floor. With the flat floor and bottom areas a relatively high resistance to lateral impact is secured, but if greater longitudinal stiffness is desired, the bottom member may be corrugated and the tops of at least some of the corrugations spot welded to the floor.
  • Cross bracing is furnished by the turned up portions at the front 9 and back H] of this floor area (as best seen on Figure 5).
  • the upper and low- 1' sections may be in contact and spot welded to avoid relative motion and consequent noise,
  • Figure 9 shows a section through the trunk and rear fenders. This consists essentially of an elliptical section box beam 6 or 8 above each wheel and suitably caved in on its under side to provide clearance from the wheel with extreme spring deflection and to form a splash curtain at its outer edges.
  • the transmission is advantageousiy; connected to thefront, wheels: for front wheel drive; and, as shown in-Frigures 5 and 24, has its change speed gear box All; or other torque-converter trans mission-directly behind the motor with its output
  • This expedient-the'differential'hasbeen-placedforward of the transmission and underthe rear mainbearing ct the motor, thusgiving a most com-.--
  • InJlig-ure 11 the: parallel sloping dash lines indicate the direction of draft of the stamping dies: Itvwillbe seen'that all pa-rts -can be drawn with no 1 undercutsby a single :die from a: single-- piece of sheet metal; 'The desig-n also lends itself; wheresmaller'stampingsare: preferred, to division into three stampings, a forward sectionincluding:
  • cowl .andztoroidal parts a: central section for the dash, the passenger space and back of'the reanseat; and? a.rear section including theluggage compartment and rear fenders.
  • gasoline tank 46 located the gasoline tank 46, preferablya'little' above fiushrelation with thenbottom face. of fthe carbody.
  • material 48 e. g., a rubber block or blocks or as-- phalt; impregnated fibrous; board may. be assembledibetween them so: asto damp. any resonancewithin the structure.
  • toroidal ring 31- welded: edgebut; also'to. permit the-.locatlon of the headlights.
  • Figurey2 shows the toroidal mouth: 31 with; the headlampsimounted in its extremities recessed" enough for. protection from minorqcollisionz but. not so far: as; to interfere-with light: distribution over the road;
  • cooling may: if: desired. also furnish. ventilation. to: the; body: interior. through. communie CatlIlg openings in; the: beams 6 and. 8.
  • the shells 2 and 4 are preferablyns e- Qured together at the seams 54 by a continuous ed weld, T ma be qoh hhh hhth 'Qh weld, but ortlinarily it is better eith tqfrrj1al;e a continuous braz e or to leave flanges as shownin Figure 22 and spot weld these at appropriate intervals.
  • the interior is more apparent than realy liminat on he P FQQ Q P BT structural parts and the utilization of almost all of the: steel so that its strength is utilized.
  • the entire shellcan be .r arle oi steel of the thichnessnornrally used for bumpers and still achieve substantial savings of eight and cost.
  • the strhcturejlo yer hanw l ras her ofore be 93 3 hhd, h i t bilitfx tq the car'.
  • eithe t out arm fi l i se a a an a best shown Figure 24 is pivoted on an axis which passes through the area of Contact offlthe tire on, the road, adva a eously a s ort, istance inw rd from the center of the contactarea and on or preferably close to the vertical axial plane ofthe wheel.
  • Ihe cushioning spring '18 and the shock absorbersuflfi are connected to the endof each wheel arm.
  • the static weight of the car is carried by the coil springs 18 (or if desired by other type springs).
  • These coil springs 18, with or without some resilient flexing of the trailing arm portions M accommodate the vertical movements of the wheels in passing over irregularities in the road and in absorbing shocks of up and down movements of the car.
  • the rubber sleeves 86 are near or at their unstressed condition; but, when the wheels move up or down, they are stressed in torsion and thus add their resilient forces to those of the springs, respectively.
  • the rubber torsion spring is designed to be relaxed at, or even somewhat below, the position with the body fully loaded, so that the coil spring (or other metal spring) and the rubber torsion spring prestress one another, it will allow the use of a soft spring (i. e., with relatively low load/deflection rate) while holding the body to a reasonable height and range of vertical movement.
  • the rubber spring has a relatively low load-deflection rate on each side of its relaxed position which gradually increases as the defiection is increased in either direction.
  • is drawn into the shell 4 at the highest part of the fender so that it provides space for a very long spring, far in excess of what is possible with present day passenger automobiles, thus permitting better spring characteristics and a softer ride. If desired the recess 8
  • each of the four wheels of the assembled structure is supported independently of all the others and is independently sprung, thus providing good ground adherence and freedom from vibration.
  • This mounting and springing of the wheels individually is only made possible by the superior rigidity of the improved self-framing body structure of the present invention with its high resistance to twisting and bending even in 12 the fender section forward of the front wheels.
  • the angular relations in the wheel mounts 60 and 68 although not essential to the other features of the invention, give important advantage.
  • the small angle of the axis of shaft portions 12 to the axis of its wheel at 16 determines the height of the roll center and thus controls in part the tendency to roll on curves. This angle should be small, however, since a greater angle would result in tilting the axis of rotation of the wheels when they roll over an obstruction or into a hole, with the consequence that gyroscopic forces of precession would interfere with normal steering. If the angle is substantial, then there is an actual toeing in or out, as the wheel moves down or up and that will, of course, tend to steer the car to one side or the other. By adjusting this angular relation, and especially with the center of gravity kept low, one gets nearly non-gyroscopic steering and stability with freedom from roll.
  • the front wheel brakes are carried by the power plant unit at 83 so that the braking torque is applied to the driving shafts 84. This both reduces the unsprung weight and the complication of design around the steering knuckles and wheel axles and it relieves the trailing arms 60 of the direct reaction torque to the braking.
  • Such an arrangement is well known in the art, e. g. the Cord front wheel drive automobiles.
  • the brakes will be at the hubs and secured to the trailing arms 68.
  • Operating linkage for brakes and steering may be conventional and is largely omitted in order to show more clearly the more distinctive features of the design.
  • the driving shafts 84 will, in accordance with established practice for cars steering and driving the same wheels, have universal joints at the differential and at the steering knuckles SI. These may, advantageously, be constant velocity universal joints, although for simplicity they are shown as conventional knuckle joints.
  • the motor and transmission of the improved automobile of the present invention are preferably located as far forward as is practicable and advantageously with the motor in front of the axles of the front wheels.
  • the motor 88 and the transmission 40 and differential 90 are connected together in a compact unit power plant that can be removed bodily as a single package from the self-framing body structure.
  • this unit may also include the brakes, the braking torque being applied through the drive shafts, and thus the brake fluid conduits or brake linkage etc., can be kept short and enclosed.
  • the muffler and exhaust pipe are also a part of or carried on this unit compactly arranged and discharging under the car, which being a tight integral sheet cannot leak carbon monoxide into the passenger space.
  • the self-framing body structure is entirely open beneath the motor and transmission so that when the power plant unit is disconnected from the three supports 38 and 39, the entire assembly essays-es their outer steel sleeves secured, advantageously byv welding (by which term I include brazing), in the'v'ertical indentations forsupports 38, and at't'he. rear on the similarcushion' mounting 39' secured in an indentation". at the rear of the motor well 36.
  • the power plant as a whole. can becarried nearer thev ground, than in present. day automobiles, ,thus. further. contribute ing to. lowering the center ofgravity, of the car as a whole and also carrying the center ofgravity further. forward. to. obtain an arrow stability, i..e., to assure that therestofthe car. will follow the. steering wheels even when traction is lost in. askid, and will not swing around.
  • the lowering of the .power plant. also permits a lowerhood top; and this plus the location of the wheels at. the rear of the engine I have turned to advantage by. sloping the forward section of the car from. the cowl. to the front. tip so that the driver gets a full view of the road to only a few feetin front of the car.
  • the platform or passenger seating part. of the body is preferably the full width. of the can extending to the outside of the wheels so that each seat. will comfortably .seat three pas taken of. the roof or top of thepassenger body.
  • the top may be of any suitabl'edesign and may be attached to the self-framing'body structure by brackets, telescoping parts or otherwise.
  • a simple top construction is shown in which longitudinallyextending tubular frame pieces I02 at each side are arched to provide head room and space for the doors. These are attached to the unitary body' structure at points behind the rear seat and'at the outer corners of" the cowl.
  • These frame members maybe of any beam shape to provide the required resistance to bending and
  • The" rear wall of the the domed steel top- I06 may be welded thereto to make anintegral top structure provided? withafront Window I08 and-a rear-window I Ill.
  • the ends of the frame members I02 are receivedirr holes in the uppershell 2' and arewelded in placev and their lower ends which extend against the lowershell. 4- may be spot welded thereto; The edge of the top lflfi-where-it meets the shell 2 may be welded or brazed togive-greater strength. and a smoothjcint which will hold a; fine; finish without cracking;
  • the top and nose portion. of. the car will prefer.- ably be so designed as to oiler'a minimumxof-resistance to the air. Since: a complete. streamline shape'is impracticable because it would lead to excessive overall car-length (atleast 30 feet forra carthat isfi'feet high),.I prefer to utilize what might be termed a front half streamline shape. In sucha: design the portion; of the car fromthe highest point'of' the roof forward is shaped essentially as the front .half of an airfoil. Such halffstreamline shape puts, the center. of windv pres:-
  • Iii-ordinary cars the air resistanceof theunderside of the frame and body structureis far in excess of that on.theupp,er.exposedsurfaces.
  • the frame members, springs, tanks, axles, etc. present an altogether cluttered array-- of obstructions. and turbulence pockets to: give a maximum air drag against. the road.
  • the smoothv stamping of the underbody in the present invention is in contrast. Piping, wiring, etc. can becarried through. thebox beams Band 8 advantageously, being laid. into the lower shell 4'. before the, two shells. 2 and 4 are welded. or otherwiseysecured together.
  • the gasoline tank is advantageously made. of such shape that it fits the recess; in. the underbody and contributes to the'smooth streamline form of the underbody; or, if thatis not convenient, a cover may be added to give :such form to the underbody.
  • the hollow parts of the frame and body structure of the present invention be used to enclose the wiring and conduits for gasoline, brake fluid, etc. but the hollow shell itself may be used as ducts for introducing fresh air into the passenger compartment, as, for example, by providing openings H6 at the front or at unstressed areas at the sides or bottom, and suitably controlled openings from the interior of the shell into the passenger compartment.
  • the assembly shown in Figure 3 while the front end of the structure is still open, may be dipped in any suitable coating liquid which will coat both the inside and the outside and render it resistant to corrosion.
  • drainage openings may be provided through the shell at low points to drain any liquid which may get into the interior of the body through any of the necessary openings.
  • Such drainage openings are not large enough to detract to any appreciable extent from the strength of the structure and can be located in substantially unstressed areas.
  • I Glove, radio and instrument cases or compartments can be inserted in the dashboard by cutting out the necessary holes, preferably in relatively unstressed areas or supporting the opening by the inserted box.
  • srch a hole extends across the right hand side of the dashboard and inserting a glove compartment box, which is latched in place. Smaller holes are cut on the left side in which the instruments are mounted; and the right hand hole gives access totheir backs for connecting and disconnecting.
  • cowl ventilators, access openings, etc. may be provided as required.
  • an instrument panel may be made up as a unit and inserted into a single opening in the dash as close to the normal line of view as pos sible.
  • the combined frame and passenger body structure of the present invention which in its entirety is essentially a beam shaft, presents many important advantages over the present day automobile frame and body structures. Not only is the weight substantially reduced for a given structural strength, with corresponding savings in material cost and operating expenses, but there is a marked increase in stability, comfort and convenience and especially in the safety against serious accidents.
  • resistance to bending requires flange height, or, ideally, an I beam.
  • Resistance to twisting requires an enclosed area or a tube.
  • the combination of the two in a beam shaft would then be an elliptical tube.
  • the body structure of the present invention in its entirety approximates an elliptical tube flattened and pinched to provide space for the necessary components of the automobile and the passenger accommodations.
  • An important feature of the invention, therefore, is that the provision of such space has been effected without loss of the prime requirement of structural resistance, namely, the greatest distance possible from the axis of deformation to the active structural material.
  • a cold rolled sheet steel shell of thickness .06 or about A self-framing body shell such as herein shown for a six-passenger automobile would then have a weight about onehalf the weight of the corresponding parts of a standard passenger automobile of the same capacity.
  • the empty, so-called curb weight of a complete standard passenger automobile is about 3300 pounds, of which 1500 pounds is the weight of the mechanical components, 300 pounds the weight of the seats and other interior parts, while the remaining 1500 pounds is what can properly be called structure (although not a very efficient structure since it comprises a strong, but not stiff, truss type frame surrounded by fragile sheet metal skin which has been forced to become a part of the structure by reason of necessarily rigid connections).
  • a complete automobile such as herein shown by reason of its use of substantially all the material in structural parts and its elimination of separate framing, lighter and stronger combined frame and body structure and the simpler and lighter front and rear suspension and transmission assemblies, would have its curb weight for the same capacity reduced by nearly 1000 pounds, e. g., to a curb weight of about 2300 pounds as compared with the 3000 pounds curb weight of the present standard passenger automobile.
  • These weight figures do not take into consideration the consequent savings in the weight of the power plant and transmission elements required for identical performance in such a lighter car.
  • Aluminum alloy of the types used in'aircraft of about 33%" thickness can be used instead of steel with further v eight reduction.
  • Other sheet materials such as plastics, indurated fibrous sheets, etc., can also be used.
  • the body made of sheet steel of a thickness corresponding to that used in present day bumpers, being essentially all bumper. It may here be added that, where desired, bright metal guards or rubber pads, etc., may be arranged on the more exposed parts of the body to protect the body finish in parking, such a guard for example covering the weld seam 54 as illustrated at 55 in Figure 23, and if desired having a rubber backing.
  • the lower faces of the fender parts of the shell structure are recessed to receive the coil springs, suspension arms and motor mountings, thus acquiring increased local strength through the sharp curvature at the recesses.
  • Still another important advantage of the novel structure herein shown and described is the reduction of the wheel suspension to the simplest and most robust form, each wheel being carried on a single independent trailing arm having a p1votai or hinge mounting in a sleeve fastened nto a dimple.
  • this hinge connection is herein shown as inclined to the longitudinal axis of the car body to increase the roll resistance, it will be understood that, by a change of the direction of this axis of swing, the characteristics of any other form of wheel support may be had, from the non-gyroscopic action of up and down motion of the wheel in its own plane to the roll resistance of a'wheel moving in an arc of a circle around the longitudinal axis of the car, as herein shown and described.
  • This particular wheel support requires extreme rigidity of the structure forward of the front wheels, a feature provided bythe novel structure of the present invention but foundin no other existing frame and body structure.
  • the upper and lower shells .2 and 4 are each shown as formed from a single piece of sheet steel so designed that each may be preformed into its desired shape by a single stroke of the hydraulic press, it will be understood that the invention is not limited to this particular way of preforming the shells nor to prefor ming each she-ll from a single sheet.
  • rigures 28 and 29 is shown another embodiment in which the top and outer part of the body are made in a unit and a third piece is the inner body part.
  • the two ends of the car so are essentiallythe same as in the ed above, but in this case the floor and unoeroody are one piece while the third piece out out as show to nd the transverse box beams 9a e and welded along their edges, to
  • a self-framing bod structure for private passenger automobiles which comprises an under body section and an upper body section securedtogether, said sections combining to form integral body-long box beams extending along the body at each side thereof and continuing in curved end portions over the wheels to form fenders, said box beams being formed by overlapping spaced portions of said sections respectively and longitudinally engaging portions on said sections, and said sections also forming an integral body-wide cross box beam by overlapping portions of said sections each constituting an opposite side thereof and being secured together in said box beam structure, said body-long box beams being connected by said cross beams, said upper and under body sections between said fender portions near one end having registering apertures and having between said apertures an annular wall surrounding a space for mounting a motor, and having transverse walls spaced fore and aft, respectively, from said annular wall, whereby said annular wall, transverse Walls and fender portions constitute a toroidal ring around said motor space, and motor mounting means on said ring adjacent said motor space.
  • a self-framing body structure for private passenger automobiles which comprises an under body section and an upper body section secured together, said sections combining to form in tegral body-long box beams extending along the n merely closes the longitudinal body at each side thereof and continuing in curved end portions over the wheels to form fenders, said box beams being formed by overlapping spaced portions of said sections respectively and longitudinally engaging portions on said sections, and said sections also forming an integral body-Wide cross box beam by overlapping portions of said sections each constituting an opposite "side thereof and being secured together in said box beam structure, said body-'- long box beams being connected by said cross beams, said upper and under body sections be' tween said fender portions near one end having registering apertures and having between said apertures an annular wall surrounding a space for mounting a motor, and having transverse walls spaced fore and aft, respectively, from said annular wall, whereby said annular wall, transverse walls and fender portions constitute a toroidal ring around id
  • a self-framing body structure for private passenger automobiles as defined in claim 1, the front of said toroidal ring having registering openings through its walls and an annular wall connecting said openings whereby said front end constitutes a cross beam structure of toroidal form with its axis longitudinal of the automo bile and with a forwardly directed mouth open to provide for inflow of cooling air into said motor space.
  • 6-.- .A private passenger automobile which com prises a self-framing body structure having an under body section and an upper body" section; secured together, said sections combining to fo integral body-long box beams extending ales-g the body at each side thereof and formed by overlapping spaced portions of said sections respectively and longitudinally engaging portions on said sections, and said sections also forming an integral body-wide cross box beam by overlapping portions of said sections each constituting an opposite side thereof and being secured together in said box beam structure, said bodylong box beams being connected by said cross beams and which is further characterized by the box beams and cross beams extending substantially continuous around the eriphery of the body.
  • a private passenger automobile which comprises a self-framing body structure having an under body section and an upper body section secured together, said sections combining to form integral body-long box beams extending along the body at each side thereof and formed by overlapping spaced portions of said sections respectively and longitudinally engaging portions on said sections, and said sections also forming an integral body-wide cross box beam by overlapping portions of said sections each constituting an opposite side thereof and being secured together in said box beam structure, said body-long box beams being connected by said cross beams and which is further characterized by one of the cross beams being located at the front of a passenger space where it forms the dashboard and cowl, another of said cross beams being at the rear of the passenger space where it forms a bulkhead between the passenger and luggage compartments and a third being within said passenger space and spaced rearwardly from said dashboard portion where it forms a raised platform for a seat, thus giving crash protection to the passenger compartment.
  • a self-framing body structure having an underbody section and an upper body section secured together, said sections combining to form integral body-long box beams extending along the body at each side thereof and formed by overlapping spaced portions of said sections respectively and longitudinally engaging portions on said sections, and said sections also forming an integral bodywide cross box beam by overlapping portions of said sections each constituting an opposite side thereof and being secured together in said box beam structure, said body-long box beams being connected by said cross beams and the underbody and upper body sections each being body-long and body-wide and combining to form all of said beams, and a top section being secured to said upper body section at the front and rear of the passenger space on the tops of cross beams located respectively at those positions.
  • a self-framing body structure having an underbody section and an upper body section secured together, said sections combining to form integral body-long box beams extending along the body at each side thereof and formed by overlapping spaced portions of said sections respectively and longitudinally engaging portions on said sections, and said sections also forming an integral bodywide cross box beam by overlapping portions of said sections each constituting an opposite side thereof and being secured together in said box beam structure, said body-long box beams being connected to said cross beams and said underbody and upper body sections being each 20 body-long and body-wide and each being a single drawn sheet metal stamping, and by their being secured together at their edges into a unitary beam-shaft structure.
  • the body structure as defined in claim 9 which is further characterized by the sheet metal of which said body stampings are made being of stiffness at least equal to sheet steel of one-sixteenth inch thickness.
  • a private passenger automobile which comprises a self-framing body structure as defined in claim 1 which is further characterized by said underbody and upper body sections being welded together into a unitary beam shaft structure having a tubular opening from end to end whereby wiring, cables and piping may be carried in the body structure and protected from external damage, the bottom of the underbody being substantially smooth in a fore and aft direction for stream-line air flow to minimize air drag along the road.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Body Structure For Vehicles (AREA)

Description

May 5,1953 H. KARLBY AUTOMOBILE? Bony STRUCTURE Filed July 7, 1949 a Sheets-filieet 2 W @M- Mm? 3nventor y 5 H. KARLBY 2,637,592
AUTOMOBILE BODY STRUCTURE Filed July 7. 1949 8 Sheets-Sheet 5 (Ittornegs May 5, 1953 H. KARLBY 2,637,592
I AUTOMOBILE BODY STRUCTURE Filed July 7, 1949 v 8 Sheets-Sheet 4 v Jnnentor HE/VNIIVG- ff (Ittornegs May 5, 1953 H. KARLBY AUTOMOBILE BODY STRUCTURE 8 Sheets-Sheet 5 Filed July 7, 1949 Snnentor hE/V/V/A/G K4943 Y I5 I M, 47 m 1' vi @141 (Ittornegs H. 'KARLBY AUTOMOBILE BODY STRUCTURE May 5, 1953 Filed July 7. 1949 8 Sheets-Sheet 6 v Snnentor Kmeza Y y 5, 3 H. KARLBY 2,637,592
AUTOMOBILE BODY smucwag:
Filed July 7. 1949 8 Sheets-Sheet 7 3nnentor fig/wwA/ KA RBY May 5, 1953 Filed July 7, 1949 .KARLBY 2,637,592
AUTOMOBILE BODY STRUCTURE 8 sheets sheet 8 3nventor HEN/W/VG KARLBY Gttomegs Patented May 5, 1953 UNITED STATES PATENT OFFICE AUTOMOBILE BODY STRUCTURE fHenning'Kaflby, Pittsburgh, Pa.
Application July 7, 1949, Serial'No. 1413;519
11- Claims.
This invention :relates :to passenger automobile :structures of the so-called pleasure near 1 type ,and has i for? its general object to strengthen and lightensuch structuresxandat the same'time to-improve the overall .efiiciency, stability, rideability and durability-of automobiles, while-im- --.proving--their fitness forg quantity. production.
. iders, and much of the body, are vessentiallyncnstructural .in-present automobile structures, and
therefore; because-of their light construction, re- .quiresecondary members for .the support and looationthereof and heavier non-structural members hung .on the rexterior aszbumpers to pro- .tect the lighter, fenders and body.
"Ithas been .proposed to weld frame members andi-body. .skin,-.i. .e., .the structural members and.
weather shields, into a unit typeubody, andin the .case .of some i of .the. smaller European cars Ha part. of the: structural "framing has been made -.oi? .the .same sheet metal as -.the .body.-skin :or
weather shield byben-dingior folding itlooally pinto:angle.orJboxsections. .'Such structures have had to be built up of numerous pieces :held in complicated jigs. for assembly. and welding, and
.may be subject i to serious trapped stresses .as laconsequence of this..-method of manufacture. v.Nor. have they .realized .the .hidden 1 possibilities -..of .savings in .material weight, and production :cost .or. of structural simplification and improve- ;ment .of operating efficiency, safety and comfort which are achieved bythe present invention.
'.The bending .anditwisting resistance required in the modern commercial automobile structures .issupposed-to .be .furnished by a combination .oftheframe. and the body, .atjbest rigidly welded together. .However, since-the outer sheet metal thickness of the .body is. about one thirty-second of aninch only, it is ,quiteunstable by itself and .must be supported and braced by a very large -L1'll15fib6l" of secondary framing. elements ofhighly complicated shape. This leads to: averyrlabori- .ous and very expensive -.prooess .of bringing the numerous parts. needed for :such za'tstructure into rcorrect alignment.
;.In;spite -;of .the complication {of the ;p resent automobile structure andthe high resultant cost thereof, the structural efiiciency of this framework is low. Such a body-frame assembly weighingfrom 1500 to 2000 pounds still has-nomore twisting and bending resistance than that of a tubeweighing only 100 pounds.
In such a body-frame construction the protection provided for the passenger in case of collision is quite incomplete. The two outside passengersonthe passenger seat straddle the main frame members of a conventional car and are thus protected only. by the thin sheet metal of the body. Thisasheet metal is so weak that instead of serving as a shield it has to depend upon .bumpers, etc., for protection against damage by-such minor impacts as result from park- .ing; and yet these sheet metal. stampings represent thelargest part of the investment needed to build automobiles, name1y, theinvestment in body and fender dies.
This expensive structure, with -,its comparatively .low bending and twisting resistance and its lackof;protectionforthe passenger, houses a power plant located .at the frontlfor driving therear wheels. This rear wheel drive not only is the: cause of much of the directional instability. of an auto. in. operation but also .brings. about .a. weight distribution whichleads to still more instability. Furthermore, although it is recognized that wheelsindividually suspended from very soft springs are the onlymeans of assuring efficient ground. adherence and freedom .from
vibration, it ,has been foundimpracticable to incorporate such individually suspended wheels in existing automobile structures by reason of the ,inabilityof :-such structures to furnish the bending-and twisting resistance necessaryin order. properly .to control such a suspension.
. In attempting tostreamline automobile bodies and also toincreasethe weather shielding, the accessibility of. the mechanicalparts of the automobile ,has been greatly reduced. In fact the inaccessibility of such mechanical components of the present day .automobile structure has reached a point where removalof the entire .front wheel :and :spring assembly .is necessary in some carsif the engine underpan is to be dis- .engaged. Moreover, the very large numberaof ,parts involved in the present body-frame structures require two miles of assembly line.
, An important object of the present invention, therefore, --is tov replace the vconglonmeration of gpartsrmakingup the body ,andframe structure 10f the present day automobile by whatisessentially a single member of vastly superior strength, lower weight and greatly reduced assembly cost, and pleasing appearance, while leaving free access to all mechanical components of the automobile.
Not only does the invention aim to increase the structural strength and reduce the weight and assembly cost of automobile frame and body structures, but it further aims to increase the overall efficiency and the operating stability of automobiles.
The unitary structure of the present invention not only replaces the conglomeration of parts making up the frame and body structure of the present day automobile, but is so designed that it will resist both bending and twisting, that it will serve as an effective shield for the occupants, that it will be so light that it will impede acceleration very little, that it will have low air drag, and that any obstruction of vision will be minimized as much as possible. To this end the invention aims to provide a passenger body structure which is essentially and in its own design such a highly efiicient beam-shaft as to serve in itself the functions of the normal frame and is of such high local impact strength as to serve in itself the functions of impact shield and bumpers.
By the term beam shaft used herein is meant a hollow structure having external walls adapted to serve like the walls of a box beam to resist bending, but also curved without sharp corners substantially throughout its periphery, so that it acts also as a shaft to resist torsion.
The present invention achieves these objects first by utilizing structurally nearly all the material used in the automobile and by making the body and fenders in a unitary beam shaft structure, a closed box beam without sharp corners and enclosing the largest possible cross sectional area.
The best shielding of passengers and the greatest economy in construction is achieved in my invention by giving the shell a simple functional shape and constructing it from two stampings (or a very few smaller parts when the investment for large stamping presses is not practicable). With this structure I need no secondary supporting structure whatsoever. Furthermore, according to my invention all mechanical components are external to, i. e., are not confused in,
the beam shaft structure. These mechanical Darts are connected to the tubular beam structure in local indentations which, because of their relatively short radius of curvature, have a high dome strength for receiving and distributing forces transmitted from the attached parts.
Stated in another way, the invention contemplates a vehicle structure in which, after delineating all of the spaces required (1) for operating parts; (2) for access to the operating parts; (3)
for carrying space and (4) access to carrying space, and the limiting planes of (a) ground clearance, (b) height, (0) width, (d) length, and (e) lines of sight for driver and passengers, a continuous space between and around these is en-' 3 closed by a hollow sheet metal shell of gauge adapted to provide necessary structural strength, smoothly curved in all directions and having a surface smoothness providing low air resistance and quiet air fiow.
By virtue of this highly rigid structure the invention contemplates a further significant improvement in the combination with this of a very simple and rugged individual wheel mounting and springing.
Still another aim of the invention is to take full advantage of such a combined frame and passenger body structure with its superior overall strength and resistance to deformation by a rearrangement of the mechanical elements of the automobile contributing much to its stability and rideability.
An important object of the invention is to eliminate the extraneous non-structural parts that were hitherto required as separate parts and also the frames and fastenings which were required for the support and positioning of such essentially non-structural elements. To these ends the invention contemplates making a selfframing passenger body structure substantially entirely with the exception of the top and a relatively few fittings, from sheet metal of relatively heavy gauge, 1. e., substantially stronger than has heretofore been used for the body skin and lighter than is ordinarily used for framing automobiles of similar capacity and performance. Advantageously, taking full advantage of the invention, the number of preformed shells required for assembly into the improved self-framing body structure is reduced to two which can be stamped from heavy sheets on production presses.
The invention in it broader aspect gives flexibility of design to meet functional requirements. In its spe:-ific embodiment as hereinafter set forth, the passenger space is first determined beginning with the desired comfortable seats for three people on each of two seats and with comfortable spacing for feet and legs. Beyond this passenger space at each end the wheels are arranged and motor and luggage compartments are extended 'therebeyond at the front and rear respectively. With these several spaces for power plant, for passengers, for luggage and for wheels determined, a space between and around them is enclosed by a beam shaft structure having the required road clearance in its lowest parts and having necessary clearance below lines of sight required for driving. [he shape shown is a design of funtional art, but many other designs both decorative and functional can be used, the designer having a wide latitude of choice by virtue of this invention.
Other objects and important features and advantages of the invention to which attention has not specifically been directed hereinabove will appear in the following description and claims when considered in connection with the accompanying drawings.
Although in this specification and the accompanying drawings I have shown and described a preferred embodiment of my invention and have suggested various modifications thereof, it is to be understood that these are not intended to be exhaustive nor limiting of the invention, but on the contrary are given for purposes of illustration in order that others skilled in the art may fully understand the invention and the principles thereof and manner of applying the same in practical use and be enabled to modify and adapt it in various forms each as may be best suited to the conditions of a particular use.
In these drawings in which like reference characters refer to like parts throughout:
Figure 1 is a side elevation of the complete automobile having a top attached to the basic body structure;
Figure 2 is a front elevation showing the arrangement of the air intake, headlights, etc.;
Figure 3 is an isometric view of the upper of two preformed sheet metal stampings employed in producing the-embodiment of the invention herein illustrated;
Figure 4 is an isometric view of the-lower ofthe two shells required to produce the illustrative embodiment;
Figure 5 is a view in central, longitudinal vertical section, showing the shells of Figures 3 and 4 assembled into the self-framing passenger body structure of the present invention, these. shells being welded together at their meeting edges;
Figure 6 is an enlarged view in vertical transverse section taken on line 6-6 of Figure 5, but with the motor shown in front elevation;
Figure 7 is a view in vertical section taken on line 7'! of Figure 5;
Figure 8 is a transverse vertical section taken on line 8-8 of Figure 5; i
i Figure 9 is a transverse section on line 9-9 of Figure 5;
Figure 10 is a bottom plan View of a complete automobile embodying the present invention, showing the location of the wheel supports, wheels, gasoline tank, motor, driving connections, etc.;
Figure 11 is a longitudinal, vertical section taken through the upper and lower shell assembly;
Figures 12 through 21 inclusive are diagrammatic sections through the self-framing, body structure respectively on the lines l2--|2 to 2l-2l of Figure 11;
Figures 22 and 23 are detail views showing how the shells may be secured together by bolts or spot welding;
-Figure 24 is a fragmentary sectional view of one front wheel and associated parts, particular the brake mechanism;
Figure 25 is a fragmentary sectional View taken on line 25-25 of Figure 1;
Figure 26 is a cross-section taken on line 26-46 of Figure 25;
Figure 27 is a fragmentary phantom plan view of the front end of the automobile;
Figure 28 is an exploded view of the parts which make up a self-framing body in another embodiment of the invention; and
Figure 29 is a fragmentary section through a door sill showing how the parts of Figure 28 are welded together into a box beam structure.
In the embodiment of the invention shown in the drawings, in which the basic self-framing passenger body structure is reduced almost to its ultimate simplicity with the main shell made in two halves 2 and 4,.shown individually in Figures 3 and 4, it will be seen that the upper shell has been so designed that not only does it provide its essential component shapes of which the assembled structure is made up, but that it lends itself to formation by stamping or deep drawing from sheet metal, e. g., between dies on a hydraulic press.
As shown, the twoshells 2 and 4 combine to.
form an overall beam-shaft, i. e., the two shells when welded or otherwise secured together form a hollow structure having a high stiffness/weight ratio because of its box-beam cross-section. Moreover, these shells are formed so as to provide box-beams peripherally of the automobile, especially across the front and-along the sides. Asshown, an engine Well is substantially surrounded by a torodial box beam section and the passenger space is reinforced by transverse box beam sections. Thus the body is in effect a series ofqspaces for engine, passengers and luggage,
each surrounded by box beam structures integral a with the other parts of the body. At the same time the lower surface of this body is smooth to give relatively little air drag, and to give high impact resistance by lying flat in a horizontal plane, parallel to the direction of destructive impacts.
The upper shell 2 is shaped to form the upper and inside faces of two longitudinal box beams 6 and 8, and the connecting integral cross beams 9, I0, and I2 located under the cowl and beneath the passenger seats, respectively, the floor of the passenger compartment being shown at M between the rear and front seats and at I6 between the front seat and the dash l8, which is integral with the overhanging cowl 20 which, in turn, is integral with the toroidal frame portion which serves as hood sides 22 and extends over the front wheels and forms a part of the front wheel fenders. The upper part of the rear cross beam i2 is shaped to support the back cushion for the rear seat and to constitute a part of a stiffening cross beam shape of which the upper wall 23 of the baggage compartment constitutes another part. It will be seen that the box beams 6 and 8 are carried up over the rear wheels to form a part of the integral rear wheel fenders 24, 26.
The lower shell 4, as shown in Figure 4, is likewise so designed that it can be pressed from sheet metal upon a stamping press by drawing dies. As shown the shell 4 is shaped to cooperate with the corresponding beam-forming elements of the upper shell 2 to form the structurally strong longitudinal box beams 6 and -8, the cross beams 9, Ill, and I2 etc. It is also shaped to provide recesses 24 and 26 for the .two
rear wheels, and 28 and 30 for the two front height of a convenient door sill and the need for keeping the floor low to bring the center of gravity as low as possible. Essentially this section consists of the two box beams 6 and 8 joined by an integral double floor. With the flat floor and bottom areas a relatively high resistance to lateral impact is secured, but if greater longitudinal stiffness is desired, the bottom member may be corrugated and the tops of at least some of the corrugations spot welded to the floor.
Cross bracing is furnished by the turned up portions at the front 9 and back H] of this floor area (as best seen on Figure 5). The upper and low- 1' sections may be in contact and spot welded to avoid relative motion and consequent noise,
,or they may be spaced e. g., by a layer of sound deadening material.
Figure 9 shows a section through the trunk and rear fenders. This consists essentially of an elliptical section box beam 6 or 8 above each wheel and suitably caved in on its under side to provide clearance from the wheel with extreme spring deflection and to form a splash curtain at its outer edges.
These two boxes are joined by the integral floor and front and rear side of ,the luggage tray. The under side of the fender assesse beams are locally recessed at p 8-1 1 to" receive" the ends' of thecompressionsprings. asmore fully described-below. A sectionthrough the car at theqfront wheels as shown on the right of Fig ure'7; is-similar; except-that ithas a single broad elliptical tube caved in' under the wheelsand bellied slightly downward for strength between the fender' portions, as there is no cent'ral space required aboveor between the structuralbeam or;beams in this cowl area.
It'issignificant that, asshown, the radius ot curvature of the upwardly and downwardly bent border areas-is less than twice the height of thecurved border: 'lfihisgives-a highdegree of rigi-dityyand strength againstimpactandthus constitutes a built-in bumperextending entirely- This effect is enhanced by thearoundithe car. out-'turnedflanges 29 and -3 3- on the sectionsl and-4 b which theyaresecured together (see: Figure 2-2) andgby the decorative bumper strip thereon.
Itavill further be-seen (Figure-'4) that the lower: shell haspressed into it, in the forward area between the cowl-20, the'inner faces -of thefrontwheelr fenders and thefront end of theauto,
anupturned flange 32;- roughly 7 annular, around a well 36' for the powerplant' unit. the peripheral edge 33 fit with corresponding flanges 34 and 35; turned down from the upper shell 2- so that this forward area is roughly toroidal in form, and'with an elliptical, toroidal mouth part 31; the edges of'these parts being weldedorotherwise held together;
The cowl ZO-andthetop-ot the hood 22 together with the portion of" shell 4 which under has them form; in the assembled} structure; anl other-strong box beam for-transversesti fening to the motor'and transmission; and to withstand its; torque and: thrust; as well as for impact resistancein event of T collision in this'area;
As 'herei'nafter-more fully set'iorth, the motor and; transmission are advantageously built;
as:,a1 unit power-plant that can be supported as:
a'unit'inthe toroidalportionI-IZ, 34, 36 by resilient mountings 38 and 39* welded to the-flange 32 This power plantunit can thus" bebodily removed from the structure;
The transmission is advantageousiy; connected to thefront, wheels: for front wheel drive; and, as shown in-Frigures 5 and 24, has its change speed gear box All; or other torque-converter trans mission-directly behind the motor with its output Bythis expedient-the'differential'hasbeen-placedforward of=the transmission and underthe rear mainbearing ct the motor, thusgiving a most com-.--
shaft at" a lower level than its input.
pact: arrangement.
The well formedby flanges fiz; 34in which the. motor: is-lccated, isadvantageouslyyopenat thebottom to permit: access to the motorand/or transmission for repairs and for. bodily. removal. of' the motor and? transmission unittofacilitate; This; also. exposes=:the motor: for. circulation of'air: for- C001!- ing; The. well ,36 is: open atthe. frontthroughthe mouth ring 31 to permit aircirculationeither major. repairs and replacements.
through the radiator of, the motor; cooling system or. directly a-round the motor; in; the: case ,of an: air-coole,d"-- unit. The; well opening 361 at the top ofthe hood is, provided with a., hinged cover; for service-accesstothe: top of. the motor. A- cross section through several parts of the motorawellcis; shown in Figures 6 and 7.. Ont-he: planeiof Figures thezbody consists OffthGhtWOf bozaboam: portions. 6;..and; 8; here: generally D:
This and shaped" and: constitutlng parts: of thefront end torus. At the bottom are shown the, mountings forthe-front wheelisuspension to: be described below. The lightacover which closes thetop of the motor well is shown in Figures l and2:
Inll igure'l" at'the, left is shownhow the beams 8 and B1merge :into :an overall box-beam section in the cowl portion .to form r the rear of the toroidal motor.- well;
InJlig-ure: 11 the: parallel sloping dash lines indicate the direction of draft of the stamping dies: Itvwillbe seen'that all pa-rts -can be drawn with no 1 undercutsby a single :die from a: single-- piece of sheet metal; 'The desig-n also lends itself; wheresmaller'stampingsare: preferred, to division into three stampings, a forward sectionincluding:
the cowl .andztoroidal parts; a: central section for the dash, the passenger space and back of'the reanseat; and? a.rear section including theluggage compartment and rear fenders.
The part1 of='the lower sh ell 1 4 which nests-with the; corresponding parti of 3 the upper shell. Tito:
form; they. cross beam l0; leaves. a recess 4min:
the-bottomrof the assembledbody inuwhich canb'e:
located the gasoline tank 46, preferablya'little' above fiushrelation with thenbottom face. of fthe carbody.
Those parts of the two shells 2 and 4 whichare brought; into face contact; at the: floor portions l lland i6; and at. thetop of therecess.44; of the assembled structuremayhe spotiwelded orotherwise secured together to increase the stifinessof thestructureqand to prevent any noiseegeneratlng relative; movement thereof; or a sound damping;v
material 48 e. g., a rubber block or blocks or as-- phalt; impregnated fibrous; board may. be assembledibetween them so: asto damp. any resonancewithin the structure.
At: theirontz end ofzthe' assembled structure,
the opening into the motor well 36 is reinforced-.1
' bye-n elliptically. toroidal ring: 31- welded: edgebut; also'to. permit the-.locatlon of the headlights.
to-edge to the two shell 2 and 4. The elliptical;
opening; as showmqisiof sufficient vertical and transverse dimensions not only to provide amouth; forgcool-mg air for the radiatori and the engine,
52 in Or behindthis opening.
Figurey2 shows the toroidal mouth: 31 with; the headlampsimounted in its extremities recessed" enough for. protection from minorqcollisionz but. not so far: as; to interfere-with light: distribution over the road; The: open. throat between: the headlamps which serves; as: the fresh air intake;
for: cooling; may: if: desired. also furnish. ventilation. to: the; body: interior. through. communie CatlIlg openings in; the: beams 6 and. 8.
toroidal mouthmayalso. constitute; the bumper,"."-'
therefore recommendedzthatrthe entire structure-v be. dipped; in' suitablerustproofing or. protective; surfacecoating materials. It is also desirablezto. coat the interior;- with: a sound: deadening.-mate:- ria1,1.which' canzbe done :by-filling itLwith a, viscous. solution. cit fused: bathof asphaltcor. rubbery Ina-- terialand then draining; withror;withoutzblowingg This.
i- Irlgranular cork, sawdust, cotton hook, or other like material: to catch on the sticky coating and be heldthe i n c in r l From the foregoing description and from an inspection of Figures 3 to 8vit will he'seen that, when the two shells? aud t arelorought together, their outer edgcsmeet to form a co tinuous' sea1r1 5 4 exterlding peripherally along the outsitleof the ox beam -h a dfi aha e e xt ns ns of h box beams 6 and 8; which form the front and rear Wheel fenders and arouiid the inside of thewell 36. In the preferrederhhocliir eht of the irrvention the shells 2 and 4 are preferablyns e- Qured together at the seams 54 by a continuous ed weld, T ma be qoh hhh hhth 'Qh weld, but ortlinarily it is better eith tqfrrj1al;e a continuous braz e or to leave flanges as shownin Figure 22 and spot weld these at appropriate intervals.
If greater rep-airability is desiremit is of course hhs hle to. s c e he twe h lls w a he by r movab e bolt hich e e'ea r strip; the ahdxbe w'e er h h h ma it sh p hhhwhihh snapspntothe encl of the web 5 3a, as shown ir t1)? vSl' lall detail View ln Fig ure 23, butthe perhl hh wht uhus we she ihih hde 21. need for access to, the interior is more apparent than realy liminat on he P FQQ Q P BT structural parts and the utilization of almost all of the: steel so that its strength is utilized. in the structure, the entire shellcan be .r arle oi steel of the thichnessnornrally used for bumpers and still achieve substantial savings of eight and cost.
Itis evident that if the body itself is built like the, present bumpers, not only are the, passengers more perfectly protecteclagainst serious .collision accidents, but thebody itself is. p oof a ai ,cruni plingt and clenting except in the most severe collisions.
Minor dents will. be filled, as in present practice, with body solder. If broader dents should occur they are best repaired lay-brazing in a piece "of-lighter steel formed to the proper shape so as to bridge the dent and grinding thelbrazed seam rr smooth. "It isfurther believes that the cost of manufacttire ofthe combined'frame and body striictilrewhen in 'mass l'erod uctio htvill besnc-h that it may be considerecf an ex'ipendable elerh'e'ht of the autorriobile tohe replaced yhere'darnage is h hs't r uire hlh rr it'. ,he o ed ha we he d ahth es 9btained'fromdriyirigthe front wheels ofthe car, ashroyided for in the above describegllqesigrtof e h hih h ia hiahd dyishii h l he pi 'esent invention, instea f 't e rea the, eliminationjof the drive ,fl oor of the .car. flfhis. seririits 1o 1 ndc he s me tim e mihat' s' hh e a,
lath i29 xlfiy hi k h h f l h l l e14 terot 'avity, the strhcturejlo yer hanw l ras her ofore be 93 3 hhd, h i t bilitfx tq the car'. This is turther aiqed b at, sle -hath hl hw h m t i led bet z een th Wheels aqyet'a i mam grouhd ear'anc e." raise -mer silt "1s 5,156 aigled by .the ayoidarrceof axlesar rd allrednction of Weight.
S e a shellfis strongest against continuous or H h 4. t well cllstrlbuted stresses, concentrated loads 1ntrodt o'ed intothelshell 23 require loadjdistributingffittings, sinceevery loading pointis' a Qotienti'al source of un'clesiralole vibration nodes, 1 reducefsiich '1, hits to a' minimum by a special sns onar gem'ent. .To this eh l each Wheel is cartietl: on. a siiigle individual trailing arm, I; its front to"the'under. side of the e: and looclystructure 'ahdjthe'povgiat three points only, each ion absorbing and damping pp e1 plant supportsare so arhethrough the two front 0 e'fpasses through or close'to i y of the pdwet afm unit." fig zn ore part ularly to Figures 6 and u e'iniderside of'the condhih l he 9 hh mlh' r h hl ti fi h h htj l he h hh hee e w h h h' t hhhshr hhahhe shh t? We thbulhr-b rtirig ar.ns EU; for thefrofit wheels 6 2 and, in Iront t th'e rear tvheel recesses, ,with similar incleritatio s or chemise; 64 'to iiehetuhslarhearingstt rents supper ng l, JMWEQ h he .W e hla hh h fies it i id hem-shaf t fhhwf Yhh e e. 12 th? the hhhf h. he in hp lt hh h h'r p'eh it ma h, 4 A h w thhsebea a r fer b ih l i somewhat a, l t 1. 31331% t e h ay t hcth e h. n e e e resis het flj llihsf rswar he- Th arms h t5 Whihh s e v y who the f n whe lsfi and the ear Whe s lh he bprf .eachaehail port on It: recei d n hhe h ht ttedv ta ular beari 3, a e wardly ex e m he r tra l n ar -4 9 t 0nll4 a d a. Wh ear n por n lit- Th heari 5 homh i hsih th ha h illu tra e a inne m t l ev key d to th shaf il ihah. u e met lu leeve secured, y set shr t'afil. n thet bh a mounti fixture 55 Welded or otherwise secureiin the recess 56. i eeFisu ezm Tthewhee bea ina po t on 5-5 in. the case. eithe t out arm fi l i se a a an a best shown Figure 24, is pivoted on an axis which passes through the area of Contact offlthe tire on, the road, adva a eously a s ort, istance inw rd from the center of the contactarea and on or preferably close to the vertical axial plane ofthe wheel. Ihe cushioning spring '18 and the shock absorbersuflfi are connected to the endof each wheel arm. 56 and til at or just beyond the point where the Wheel bearing portion joinsthe trailing a t 1 lith armh sprin s and ock abs r ers bei a comm ed i i de ati ns 81 n the inner walls of the wheel recesses of the frame an ibod stru tu Y The shaft r intlew o tio l o ea h Wheel su po ma have. a simp e he ri ei its asso- ..hiat ea li swh ha e u ri occasion l lu rication, or it may be fully secnred with the neoeste re i en rihlchne h theair h t r 68' '05 in a t qr sionally resilient conrieotifon hetvyeeh shaft hh hh l hh sleev sh hr bo was f't ruhher torsion connection. betwe'eh b ea tribe 5%} anti shaft portion 12 such: as shown at at in guv f f .v In t e mb ilhsllh shown ee pa la y F snre '7, th rnbloertorsion sleeve doesnot carrythe sh h? he? hht s ws. Pr mar asj .vildrati h haha he hlh ah as a sho k .a spihi fifdr minor road shocks, and as a supplemental suspension means tending to hold the body at a predetermined height when travelling, even though the static load would tend to push it down. As shown in this figure, the static weight of the car is carried by the coil springs 18 (or if desired by other type springs). These coil springs 18, with or without some resilient flexing of the trailing arm portions M, accommodate the vertical movements of the wheels in passing over irregularities in the road and in absorbing shocks of up and down movements of the car. At the ordinary height of the empty car the rubber sleeves 86 are near or at their unstressed condition; but, when the wheels move up or down, they are stressed in torsion and thus add their resilient forces to those of the springs, respectively. This allows the use of a softer coil spring; it renders the springing non-harmonic and progressive and shock absorbing (damping recoil) because of the inherent characteristics of a rubber spring; and when the car is driven over the irregularities of the road it tends always to come back to the neutral position of the rubber sleeve.
If the rubber torsion spring is designed to be relaxed at, or even somewhat below, the position with the body fully loaded, so that the coil spring (or other metal spring) and the rubber torsion spring prestress one another, it will allow the use of a soft spring (i. e., with relatively low load/deflection rate) while holding the body to a reasonable height and range of vertical movement. Stated in another way, the rubber spring has a relatively low load-deflection rate on each side of its relaxed position which gradually increases as the defiection is increased in either direction. By combining this with another spring which not only supports the load but stresses the rubber spring oppositely to the stress produced by the load, one gets the ordinary deflection due to road shocks, with a partially or fully loaded car, into the zone of the low load/deflection rate, thus getting the benefit of a soft ride combined with buffer action against heavier shocks and recoil, and damping of resonance.
Any tendency of the rubber to take a permanent set from its initial pre-stressing will be counteracted by its opposite stressing under loaded conditions.
When a compression coil spring is used as be mounted in the center of the coil so that only one mounting recess 8| need be formed in the shell 4 at each wheel.
The recess 8| is drawn into the shell 4 at the highest part of the fender so that it provides space for a very long spring, far in excess of what is possible with present day passenger automobiles, thus permitting better spring characteristics and a softer ride. If desired the recess 8| can be deep drawn so as to contact, and may be spot welded to the upper shell 2.
From the foregoing description it will be seen that each of the four wheels of the assembled structure is supported independently of all the others and is independently sprung, thus providing good ground adherence and freedom from vibration. This mounting and springing of the wheels individually is only made possible by the superior rigidity of the improved self-framing body structure of the present invention with its high resistance to twisting and bending even in 12 the fender section forward of the front wheels.
The angular relations in the wheel mounts 60 and 68 although not essential to the other features of the invention, give important advantage. The small angle of the axis of shaft portions 12 to the axis of its wheel at 16 determines the height of the roll center and thus controls in part the tendency to roll on curves. This angle should be small, however, since a greater angle would result in tilting the axis of rotation of the wheels when they roll over an obstruction or into a hole, with the consequence that gyroscopic forces of precession would interfere with normal steering. If the angle is substantial, then there is an actual toeing in or out, as the wheel moves down or up and that will, of course, tend to steer the car to one side or the other. By adjusting this angular relation, and especially with the center of gravity kept low, one gets nearly non-gyroscopic steering and stability with freedom from roll.
The angle of the trailing arm 14 and the fact that it extends backward and down from its mounting 56 results in the horizontal component of yield to road shocks coinciding with the direction of swinging of the arm 60 or 68 under increased loading. Thus the shock imposed by an obstruction encountered by the wheel is relieved by the horizontal and vertical yield of the trailing arm.
The front wheel brakes are carried by the power plant unit at 83 so that the braking torque is applied to the driving shafts 84. This both reduces the unsprung weight and the complication of design around the steering knuckles and wheel axles and it relieves the trailing arms 60 of the direct reaction torque to the braking. Such an arrangement is well known in the art, e. g. the Cord front wheel drive automobiles. On the rear wheels the brakes will be at the hubs and secured to the trailing arms 68. Operating linkage for brakes and steering may be conventional and is largely omitted in order to show more clearly the more distinctive features of the design.
The driving shafts 84 will, in accordance with established practice for cars steering and driving the same wheels, have universal joints at the differential and at the steering knuckles SI. These may, advantageously, be constant velocity universal joints, although for simplicity they are shown as conventional knuckle joints.
As hereinabove suggested, the motor and transmission of the improved automobile of the present invention are preferably located as far forward as is practicable and advantageously with the motor in front of the axles of the front wheels. As shown, the motor 88 and the transmission 40 and differential 90 are connected together in a compact unit power plant that can be removed bodily as a single package from the self-framing body structure. As stated above this unit may also include the brakes, the braking torque being applied through the drive shafts, and thus the brake fluid conduits or brake linkage etc., can be kept short and enclosed. Advantageously the muffler and exhaust pipe are also a part of or carried on this unit compactly arranged and discharging under the car, which being a tight integral sheet cannot leak carbon monoxide into the passenger space. Also shown, the self-framing body structure is entirely open beneath the motor and transmission so that when the power plant unit is disconnected from the three supports 38 and 39, the entire assembly essays-es their outer steel sleeves secured, advantageously byv welding (by which term I include brazing), in the'v'ertical indentations forsupports 38, and at't'he. rear on the similarcushion' mounting 39' secured in an indentation". at the rear of the motor well 36.
' The driving torque reaction ten'ds" to rotatethe power plant about its center of" gravity; so
that" the rear of the unit is driven downagainst its. cushioned support 39'. power plant well is designed with a concave-con.- vex form, domed adjacent'the' point 39 and more or less toroidal around it, whereby this reaction is met withv maximum strength. and rigidity to distribute it into the body structure.
Itwillbe seen that, by providing the laterally separated trailing arm supports 61)" for the front wheels 62' and. by locating the major part. of the power plant in front of the front wheel axles and between. the. trailing. arms, the power plant as a whole. can becarried nearer thev ground, than in present. day automobiles, ,thus. further. contribute ing to. lowering the center ofgravity, of the car as a whole and also carrying the center ofgravity further. forward. to. obtain an arrow stability, i..e., to assure that therestofthe car. will follow the. steering wheels even when traction is lost in. askid, and will not swing around.
The lowering of the .power plant. also permits a lowerhood top; and this plus the location of the wheels at. the rear of the engine I have turned to advantage by. sloping the forward section of the car from. the cowl. to the front. tip so that the driver gets a full view of the road to only a few feetin front of the car.
Aswill be noted from the. foregoing description and drawings, the platform or passenger seating part. of the body is preferably the full width. of the can extending to the outside of the wheels so that each seat. will comfortably .seat three pas taken of. the roof or top of thepassenger body.
In an open model or convertible, this is necessary; and even in the. closed sedans and coupes, etc., the top is essentially'a roof and impact shield. Torsion. and. bending. cannot be satisfactorily transmittedfrom the platform. or passenger seating part of the body to the roof or topz. Any attempt to: do so results in impaired visibility; Safety demands. that the supporting posts for the roof should be narrower than the normal distance between a mans eyes (about 2%").
With this embodiment of the present invention, the top may be of any suitabl'edesign and may be attached to the self-framing'body structure by brackets, telescoping parts or otherwise. In the illustrative embodiment of the invention a simple top construction is shown in which longitudinallyextending tubular frame pieces I02 at each side are arched to provide head room and space for the doors. These are attached to the unitary body' structure at points behind the rear seat and'at the outer corners of" the cowl. These frame members maybe of any beam shape to provide the required resistance to bending and The" rear wall of the the domed steel top- I06 may be welded thereto to make anintegral top structure provided? withafront Window I08 and-a rear-window I Ill. The ends of the frame members I02 are receivedirr holes in the uppershell 2' and arewelded in placev and their lower ends which extend against the lowershell. 4- may be spot welded thereto; The edge of the top lflfi-where-it meets the shell 2 may be welded or brazed togive-greater strength. and a smoothjcint which will hold a; fine; finish without cracking;
The top and nose portion. of. the car will prefer.- ably be so designed as to oiler'a minimumxof-resistance to the air. Since: a complete. streamline shape'is impracticable because it would lead to excessive overall car-length (atleast 30 feet forra carthat isfi'feet high),.I prefer to utilize what might be termed a front half streamline shape. In sucha: design the portion; of the car fromthe highest point'of' the roof forward is shaped essentially as the front .half of an airfoil. Such halffstreamline shape puts, the center. of windv pres:-
sure-as far back-as possible; andthis, with. the.
center of gravity brought forward,. by reason.
- of the location of the power plant in frontwof' the front wheel'axles, gives a..maximum. arrow. stability The relatively flat transverse. top does away with sideways lift or. sidewindinstability in: a cross; wind andth-e downward.com..- ponentof. they wind pressure on the sloping nose will in factadd to the front wheel" traction-when itis most .needed, that i's',.at high speed.
By this design having the. front. half ofjthe car carefully streamlinedso as to give. thesmoothest possible air flow over the body and without at.- tempt to approximate an, airfoil in the rearspor tion, I: secure a quieter car. Modern automobiles by their rough approximation tov streamlining have. brought the air flow close to the body: where it" produces excessive Wind .roar athigh speeds, which was not present with. the older. box-dike designs because of the large parasite mass. of dead air which they pushed along with them., The present streamlining; however, is not.an'd,. for reasons set". forth above, cannot be.-sufficiently perfect. togive quiet flowover the body when travelling at high speeds. Withmy design, by concentrating'on streamliningonlythezfronthalf; I -getmuch quieter flow and by: combining this with. a suitable form for structural, comfort and visibility considerations, the'flow leaves the body with a vacuum cushion over thezrear' to insulate it from the 'burble noises.
Iii-ordinary cars the air resistanceof theunderside of the frame and body structureis far in excess of that on.theupp,er.exposedsurfaces. The frame members, springs, tanks, axles, etc., present an altogether cluttered array-- of obstructions. and turbulence pockets to: give a maximum air drag against. the road. The smoothv stamping of the underbody in the present invention: is in contrast. Piping, wiring, etc. can becarried through. thebox beams Band 8 advantageously, being laid. into the lower shell 4'. before the, two shells. 2 and 4 are welded. or otherwiseysecured together. The gasoline tank is advantageously made. of such shape that it fits the recess; in. the underbody and contributes to the'smooth streamline form of the underbody; or, if thatis not convenient, a cover may be added to give :such form to the underbody.
Except for the several recesses provided for mounting the parts which are to be carried on the body, it is smoothly curved in all directions, withsecond degree smoothness (i. e., gradual changes only in radius of curvature) throughout, and approximates an egg shell form.
Not only may the hollow parts of the frame and body structure of the present invention be used to enclose the wiring and conduits for gasoline, brake fluid, etc. but the hollow shell itself may be used as ducts for introducing fresh air into the passenger compartment, as, for example, by providing openings H6 at the front or at unstressed areas at the sides or bottom, and suitably controlled openings from the interior of the shell into the passenger compartment.
To insure long life of the combined frame and body structure of the present invention, the assembly shown in Figure 3, while the front end of the structure is still open, may be dipped in any suitable coating liquid which will coat both the inside and the outside and render it resistant to corrosion. Moreover, drainage openings may be provided through the shell at low points to drain any liquid which may get into the interior of the body through any of the necessary openings. Such drainage openings are not large enough to detract to any appreciable extent from the strength of the structure and can be located in substantially unstressed areas. I Glove, radio and instrument cases or compartments can be inserted in the dashboard by cutting out the necessary holes, preferably in relatively unstressed areas or supporting the opening by the inserted box. As shown in Figure 8, srch a hole extends across the right hand side of the dashboard and inserting a glove compartment box, which is latched in place. Smaller holes are cut on the left side in which the instruments are mounted; and the right hand hole gives access totheir backs for connecting and disconnecting. In the same manner cowl ventilators, access openings, etc., may be provided as required. If desired, an instrument panel may be made up as a unit and inserted into a single opening in the dash as close to the normal line of view as pos sible.
From the foregoing description it will be seen that the combined frame and passenger body structure of the present invention, which in its entirety is essentially a beam shaft, presents many important advantages over the present day automobile frame and body structures. Not only is the weight substantially reduced for a given structural strength, with corresponding savings in material cost and operating expenses, but there is a marked increase in stability, comfort and convenience and especially in the safety against serious accidents.
As hereinabove pointed out, resistance to bending requires flange height, or, ideally, an I beam. Resistance to twisting requires an enclosed area or a tube. The combination of the two in a beam shaft would then be an elliptical tube. The body structure of the present invention in its entirety approximates an elliptical tube flattened and pinched to provide space for the necessary components of the automobile and the passenger accommodations. An important feature of the invention, therefore, is that the provision of such space has been effected without loss of the prime requirement of structural resistance, namely, the greatest distance possible from the axis of deformation to the active structural material.
To illustrate some of the practical advantages obtained by the structure of the present invention, assume a cold rolled sheet steel shell of thickness .06 or about A self-framing body shell such as herein shown for a six-passenger automobile would then have a weight about onehalf the weight of the corresponding parts of a standard passenger automobile of the same capacity. The empty, so-called curb weight of a complete standard passenger automobile is about 3300 pounds, of which 1500 pounds is the weight of the mechanical components, 300 pounds the weight of the seats and other interior parts, while the remaining 1500 pounds is what can properly be called structure (although not a very efficient structure since it comprises a strong, but not stiff, truss type frame surrounded by fragile sheet metal skin which has been forced to become a part of the structure by reason of necessarily rigid connections). A complete automobile such as herein shown, by reason of its use of substantially all the material in structural parts and its elimination of separate framing, lighter and stronger combined frame and body structure and the simpler and lighter front and rear suspension and transmission assemblies, would have its curb weight for the same capacity reduced by nearly 1000 pounds, e. g., to a curb weight of about 2300 pounds as compared with the 3000 pounds curb weight of the present standard passenger automobile. These weight figures do not take into consideration the consequent savings in the weight of the power plant and transmission elements required for identical performance in such a lighter car.
Aluminum alloy of the types used in'aircraft of about 33%" thickness can be used instead of steel with further v eight reduction. Other sheet materials such as plastics, indurated fibrous sheets, etc., can also be used.
Among the more detailed advantages of the novel construction of the present invention is the complete integration of the body shell and bumpers, the body, made of sheet steel of a thickness corresponding to that used in present day bumpers, being essentially all bumper. It may here be added that, where desired, bright metal guards or rubber pads, etc., may be arranged on the more exposed parts of the body to protect the body finish in parking, such a guard for example covering the weld seam 54 as illustrated at 55 in Figure 23, and if desired having a rubber backing.
' Another advantage of the construction which has already been mentioned above, results from the incorporation of the fenders in the self-framing body structure itself, namely that coil springs, for taking up the wheel reaction, can have a much longer space to operate in than those employed with present day automobiles and thus give superior riding qualities.
As hereinabove pointed out, the lower faces of the fender parts of the shell structure are recessed to receive the coil springs, suspension arms and motor mountings, thus acquiring increased local strength through the sharp curvature at the recesses.
Still another important advantage of the novel structure herein shown and described is the reduction of the wheel suspension to the simplest and most robust form, each wheel being carried on a single independent trailing arm having a p1votai or hinge mounting in a sleeve fastened nto a dimple. Although this hinge connection is herein shown as inclined to the longitudinal axis of the car body to increase the roll resistance, it will be understood that, by a change of the direction of this axis of swing, the characteristics of any other form of wheel support may be had, from the non-gyroscopic action of up and down motion of the wheel in its own plane to the roll resistance of a'wheel moving in an arc of a circle around the longitudinal axis of the car, as herein shown and described. This particular wheel support requires extreme rigidity of the structure forward of the front wheels, a feature provided bythe novel structure of the present invention but foundin no other existing frame and body structure.
Althouh, in the illustrative embodiment of the invention, the upper and lower shells .2 and 4 are each shown as formed from a single piece of sheet steel so designed that each may be preformed into its desired shape by a single stroke of the hydraulic press, it will be understood that the invention is not limited to this particular way of preforming the shells nor to prefor ming each she-ll from a single sheet.
Thus in rigures 28 and 29 is shown another embodiment in which the top and outer part of the body are made in a unit and a third piece is the inner body part. The two ends of the car so are essentiallythe same as in the ed above, but in this case the floor and unoeroody are one piece while the third piece out out as show to nd the transverse box beams 9a e and welded along their edges, to
itinuous structure.
have described the invention. in
n with front engine, front wheel drive it should be obvious from what has no. that same type of self-framing body home of the advantages of the inobtained with conventional axles and wheef. mountings and the self-framing body or the type herein set forth; and likewise other features forth above may be used individually but generali 2 with ess advantage than in the combination as set forth.
' I claim: I
1. A self-framing bod structure for private passenger automobiles which comprises an under body section and an upper body section securedtogether, said sections combining to form integral body-long box beams extending along the body at each side thereof and continuing in curved end portions over the wheels to form fenders, said box beams being formed by overlapping spaced portions of said sections respectively and longitudinally engaging portions on said sections, and said sections also forming an integral body-wide cross box beam by overlapping portions of said sections each constituting an opposite side thereof and being secured together in said box beam structure, said body-long box beams being connected by said cross beams, said upper and under body sections between said fender portions near one end having registering apertures and having between said apertures an annular wall surrounding a space for mounting a motor, and having transverse walls spaced fore and aft, respectively, from said annular wall, whereby said annular wall, transverse Walls and fender portions constitute a toroidal ring around said motor space, and motor mounting means on said ring adjacent said motor space.
2. A self-framing body structure for private passenger automobiles which comprises an under body section and an upper body section secured together, said sections combining to form in tegral body-long box beams extending along the n merely closes the longitudinal body at each side thereof and continuing in curved end portions over the wheels to form fenders, said box beams being formed by overlapping spaced portions of said sections respectively and longitudinally engaging portions on said sections, and said sections also forming an integral body-Wide cross box beam by overlapping portions of said sections each constituting an opposite "side thereof and being secured together in said box beam structure, said body-'- long box beams being connected by said cross beams, said upper and under body sections be' tween said fender portions near one end having registering apertures and having between said apertures an annular wall surrounding a space for mounting a motor, and having transverse walls spaced fore and aft, respectively, from said annular wall, whereby said annular wall, transverse walls and fender portions constitute a toroidal ring around id motor space, motor mounting means on said ring adjacent said motor space, and means on the exteior of said ring to which wheel suspension members may be se cured.
3. A self-framing body structure as defined in claim 2 wherein the axis of the wheel-receiving space of said fender portions is rearward of the center of said motor space.
4. A self-framing body structure for private passenger automobiles as defined in claim 1, the front of said toroidal ring having registering openings through its walls and an annular wall connecting said openings whereby said front end constitutes a cross beam structure of toroidal form with its axis longitudinal of the automo= bile and with a forwardly directed mouth open to provide for inflow of cooling air into said motor space.
.5. A self-framing body structure for private passenger automobiles as defined in claim 4, wherein openings are provided at the opposite sides of the mouth for mounting of headlamps within said mouth whereby they are protected from minor collisions by the front edge of said toroidal ring and wiring connections will be carried to them through the interior of said ring.
6-.- .A private passenger automobile which com prises a self-framing body structure having an under body section and an upper body" section; secured together, said sections combining to fo integral body-long box beams extending ales-g the body at each side thereof and formed by overlapping spaced portions of said sections respectively and longitudinally engaging portions on said sections, and said sections also forming an integral body-wide cross box beam by overlapping portions of said sections each constituting an opposite side thereof and being secured together in said box beam structure, said bodylong box beams being connected by said cross beams and which is further characterized by the box beams and cross beams extending substantially continuous around the eriphery of the body.
'7. A private passenger automobile which comprises a self-framing body structure having an under body section and an upper body section secured together, said sections combining to form integral body-long box beams extending along the body at each side thereof and formed by overlapping spaced portions of said sections respectively and longitudinally engaging portions on said sections, and said sections also forming an integral body-wide cross box beam by overlapping portions of said sections each constituting an opposite side thereof and being secured together in said box beam structure, said body-long box beams being connected by said cross beams and which is further characterized by one of the cross beams being located at the front of a passenger space where it forms the dashboard and cowl, another of said cross beams being at the rear of the passenger space where it forms a bulkhead between the passenger and luggage compartments and a third being within said passenger space and spaced rearwardly from said dashboard portion where it forms a raised platform for a seat, thus giving crash protection to the passenger compartment.
8. In a passenger automobile a self-framing body structure having an underbody section and an upper body section secured together, said sections combining to form integral body-long box beams extending along the body at each side thereof and formed by overlapping spaced portions of said sections respectively and longitudinally engaging portions on said sections, and said sections also forming an integral bodywide cross box beam by overlapping portions of said sections each constituting an opposite side thereof and being secured together in said box beam structure, said body-long box beams being connected by said cross beams and the underbody and upper body sections each being body-long and body-wide and combining to form all of said beams, and a top section being secured to said upper body section at the front and rear of the passenger space on the tops of cross beams located respectively at those positions.
9. In a passenger automobile a self-framing body structure having an underbody section and an upper body section secured together, said sections combining to form integral body-long box beams extending along the body at each side thereof and formed by overlapping spaced portions of said sections respectively and longitudinally engaging portions on said sections, and said sections also forming an integral bodywide cross box beam by overlapping portions of said sections each constituting an opposite side thereof and being secured together in said box beam structure, said body-long box beams being connected to said cross beams and said underbody and upper body sections being each 20 body-long and body-wide and each being a single drawn sheet metal stamping, and by their being secured together at their edges into a unitary beam-shaft structure.
10. In a passenger automobile the body structure as defined in claim 9, which is further characterized by the sheet metal of which said body stampings are made being of stiffness at least equal to sheet steel of one-sixteenth inch thickness.
11. A private passenger automobile which comprises a self-framing body structure as defined in claim 1 which is further characterized by said underbody and upper body sections being welded together into a unitary beam shaft structure having a tubular opening from end to end whereby wiring, cables and piping may be carried in the body structure and protected from external damage, the bottom of the underbody being substantially smooth in a fore and aft direction for stream-line air flow to minimize air drag along the road.
HENNING KARLBY.
References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 872,031 Thomas et a1. Nov. 26, 1907 1,290,958 Foster Jan. 14, 1919 1,473,194 Mayer Nov. 6, 1923 1,781,322 Delling Nov. 11, 1930 1,887,666 Van Ranst Nov. 15, 1932 2,071,592 Thompson Feb. 23, 1937 2,190,551 Swallow Feb. 13, 1940 2,254,497 Schafer Sept. 2, 1941 2,271,310 Schafer Jan. 27, 1942 2,284,988 Reid June 2, 1942 2,344,896 Phelps Mar. 21, 1944 2,358,663 Scott-Iversen Sept. 19, 1944 2,495,090 Borden Jan. 17, 1950 2,497,252 Adams Feb. 14, 1950 2,499,495 Gregory Mar. 7, 1950 2,525,339 Chausson Oct. 10, 1950 FOREIGN PATENTS Number Country Date 762,366 France Jan. 22, 1934 852,494 France Oct. 30, 1939 940,939 France June 14, 1948
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Cited By (42)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE948120C (en) * 1954-02-22 1956-08-30 Daimler Benz Ag Roof arrangement of a vehicle, in particular a motor vehicle
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US3010756A (en) * 1956-11-02 1961-11-28 Daimler Benz Ag Frame structure for motor vehicles
US3022105A (en) * 1959-09-21 1962-02-20 Tjaarda John Composite automobile design
US3047331A (en) * 1958-03-01 1962-07-31 Porsche Kg Frame construction for vehicles
US3075600A (en) * 1959-10-06 1963-01-29 Willys Motors Inc Independent driving steering wheel suspension mechanism
DE1153639B (en) * 1954-01-21 1963-08-29 Daimler Benz Ag Subframes for motor vehicles
US3168344A (en) * 1960-11-15 1965-02-02 Daimler Benz Ag Automobile cowling
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US3339967A (en) * 1964-08-20 1967-09-05 White Motor Corp Vehicle cab
DE1275372B (en) * 1963-09-28 1968-08-14 Porsche Kg Motor vehicle with a car body made of plastic
US3423122A (en) * 1966-12-29 1969-01-21 Budd Co Unitized automobile body construction
DE1680609B1 (en) * 1965-03-26 1969-10-23 Bayer Ag Self-supporting floor pan for the bodies of motor vehicles
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US5741045A (en) * 1995-10-19 1998-04-21 Chrysler Corporation Car body part with hidden bonding surface
US5806620A (en) * 1995-10-27 1998-09-15 Chrysler Corporation Unitary one-piece automobile hood, fascia, and front fender assembly
US5934745A (en) * 1995-10-06 1999-08-10 Daimlerchrysler Corporation Motor vehicle body
US6113178A (en) * 1998-08-31 2000-09-05 Trw Vehicle Safety Systems Inc. Vehicle energy absorption apparatus
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US6698539B2 (en) * 2002-04-09 2004-03-02 Almarv, Llc Intake apparatus for feeding air to engine compartment
US6705667B1 (en) * 1999-04-16 2004-03-16 Daimlerchrysler Ag Supporting structure for a motor vehicle
US20050179242A1 (en) * 2004-02-03 2005-08-18 Chernoff Adrian B. Vehicle front seat configuration
US20050189791A1 (en) * 2004-02-27 2005-09-01 Chernoff Adrian B. Automotive lower body component and method of manufacture
US20060186699A1 (en) * 2004-12-30 2006-08-24 Davis Eric A Reduced-size vehicle with compartments providing buoyancy
US7617904B1 (en) * 2006-05-01 2009-11-17 Brp-Powertrain Gmbh & Co Kg Transmission for vehicle
US20100019538A1 (en) * 2008-07-24 2010-01-28 Kiley Matthew P Modular Architecture for Combat Tactical Vehicle
US20110133518A1 (en) * 2009-12-03 2011-06-09 GM Global Technology Operations LLC Chassis structure of a motor vehicle body
US20120104793A1 (en) * 2010-10-29 2012-05-03 Aptera Motors, Inc. Automotive vehicle composite body structure
US10259507B1 (en) * 2018-03-22 2019-04-16 Honda Motor Co., Ltd. Skid plate and underbody assembly for use with an off-road vehicle

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Cited By (68)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2800359A (en) * 1952-10-25 1957-07-23 Gen Motors Corp Forward end of a self-supporting vehicle body
US2814524A (en) * 1953-04-22 1957-11-26 Porsche Kg Self-supporting bodies of synthetic material for motor vehicles
DE1153639B (en) * 1954-01-21 1963-08-29 Daimler Benz Ag Subframes for motor vehicles
DE956564C (en) * 1954-02-01 1957-01-17 Daimler Benz Ag Passenger car with a central part of the vehicle body that encloses the passenger compartment in the shape of a hood
DE948120C (en) * 1954-02-22 1956-08-30 Daimler Benz Ag Roof arrangement of a vehicle, in particular a motor vehicle
US2876037A (en) * 1955-01-17 1959-03-03 Gen Motors Corp Vehicle body shell
US2856226A (en) * 1955-01-19 1958-10-14 Gen Motors Corp Vehicle frame assembly
US2908528A (en) * 1955-09-21 1959-10-13 Kaiser Aluminium Chem Corp Utility automotive vehicle
US3010756A (en) * 1956-11-02 1961-11-28 Daimler Benz Ag Frame structure for motor vehicles
US3047331A (en) * 1958-03-01 1962-07-31 Porsche Kg Frame construction for vehicles
US3022105A (en) * 1959-09-21 1962-02-20 Tjaarda John Composite automobile design
US3075600A (en) * 1959-10-06 1963-01-29 Willys Motors Inc Independent driving steering wheel suspension mechanism
US3002782A (en) * 1960-04-22 1961-10-03 Karl F Jahn Unitary frame and body for a wheeled vehicle
US3168344A (en) * 1960-11-15 1965-02-02 Daimler Benz Ag Automobile cowling
US3266591A (en) * 1963-07-17 1966-08-16 Kaiser Jeep Corp Military vehicle
DE1275372B (en) * 1963-09-28 1968-08-14 Porsche Kg Motor vehicle with a car body made of plastic
US3339967A (en) * 1964-08-20 1967-09-05 White Motor Corp Vehicle cab
DE1680609B1 (en) * 1965-03-26 1969-10-23 Bayer Ag Self-supporting floor pan for the bodies of motor vehicles
US3423122A (en) * 1966-12-29 1969-01-21 Budd Co Unitized automobile body construction
JPS4960421U (en) * 1972-09-06 1974-05-28
JPS509919U (en) * 1973-05-24 1975-01-31
JPS57122Y2 (en) * 1973-08-16 1982-01-05
JPS5042415U (en) * 1973-08-16 1975-04-30
JPS50117530U (en) * 1974-03-07 1975-09-25
JPS542490Y2 (en) * 1974-04-01 1979-02-02
JPS50127122U (en) * 1974-04-01 1975-10-18
DE3444377A1 (en) * 1984-12-05 1986-06-12 Huss, Heinrich, 6054 Rodgau BODY
US5011217A (en) * 1988-09-15 1991-04-30 Clark Equipment Company Unified frame/body assembly for vehicle
US5020846A (en) * 1989-05-30 1991-06-04 Ford Motor Company Reinforcing insert for convertible vehicle
US5934745A (en) * 1995-10-06 1999-08-10 Daimlerchrysler Corporation Motor vehicle body
US5741045A (en) * 1995-10-19 1998-04-21 Chrysler Corporation Car body part with hidden bonding surface
US5806620A (en) * 1995-10-27 1998-09-15 Chrysler Corporation Unitary one-piece automobile hood, fascia, and front fender assembly
US6113178A (en) * 1998-08-31 2000-09-05 Trw Vehicle Safety Systems Inc. Vehicle energy absorption apparatus
US6705667B1 (en) * 1999-04-16 2004-03-16 Daimlerchrysler Ag Supporting structure for a motor vehicle
US20030037971A1 (en) * 2001-08-23 2003-02-27 Chernoff Adrian B. Vehicle belly pan
US6843336B2 (en) * 2001-08-23 2005-01-18 General Motors Corporation Vehicle belly pan
US6698539B2 (en) * 2002-04-09 2004-03-02 Almarv, Llc Intake apparatus for feeding air to engine compartment
US20050179242A1 (en) * 2004-02-03 2005-08-18 Chernoff Adrian B. Vehicle front seat configuration
US7310878B2 (en) * 2004-02-27 2007-12-25 Gm Global Technology Operations, Inc. Automotive lower body component method of manufacture
US20050189791A1 (en) * 2004-02-27 2005-09-01 Chernoff Adrian B. Automotive lower body component and method of manufacture
US20100194088A1 (en) * 2004-12-30 2010-08-05 Davis Eric A Reduced-size vehicle with large internal voids
US7942447B2 (en) 2004-12-30 2011-05-17 American Off-Road Technologies, Llc Frame design for reduced-size vehicle
US20070257479A1 (en) * 2004-12-30 2007-11-08 Davis Eric A Reduced-size vehicle with large internal voids
US20070257516A1 (en) * 2004-12-30 2007-11-08 Davis Eric A Exhaust and cooling systems for implementation in reduced-size vehicle
US20060192375A1 (en) * 2004-12-30 2006-08-31 Davis Eric A Frame design for reduced-size vehicle
US7537499B2 (en) 2004-12-30 2009-05-26 American Off-Road Technologies, Llc Reduced-size vehicle with compartments providing buoyancy
US9266580B2 (en) 2004-12-30 2016-02-23 American Off-Road Technologies, Llc Reduced-size vehicle with large internal voids
US7644791B2 (en) 2004-12-30 2010-01-12 American Off-Road Technologies Inc. Exhaust and cooling systems for implementation in reduced-size vehicle
US8783720B2 (en) 2004-12-30 2014-07-22 American Off-Road Technologies, Llc Reduced-size vehicle with complementary internal compartments and suspension system components
US7658411B2 (en) 2004-12-30 2010-02-09 American Off-Road Technologies Llc Reduced-size vehicle with large internal voids
US20100108428A1 (en) * 2004-12-30 2010-05-06 American Off-Road Technologies, Llc Exhaust and cooling systems for implementation in reduced-size vehicle
US20060186699A1 (en) * 2004-12-30 2006-08-24 Davis Eric A Reduced-size vehicle with compartments providing buoyancy
US8622428B2 (en) 2004-12-30 2014-01-07 American Off-Road Technologies, Llc Reduced-size vehicle with large internal voids
US20060197331A1 (en) * 2004-12-30 2006-09-07 Davis Eric A Reduced-size vehicle with coplementary internal compartments and suspension system components
US7954853B2 (en) * 2004-12-30 2011-06-07 American Off-Road Technologies, Llc Reduced-size vehicle with complementary internal compartments and suspension system components
US8191929B2 (en) 2004-12-30 2012-06-05 American Off-Road Technologies, Llc Reduced-size vehicle with large internal voids
US8191677B2 (en) 2004-12-30 2012-06-05 American Off-Road Technologies, Llc Exhaust and cooling systems for implementation in reduced-size vehicle
US20110198831A1 (en) * 2004-12-30 2011-08-18 American Off-Road Technologies, Llc Frame design for reduced-size vehicle
US20110198830A1 (en) * 2004-12-30 2011-08-18 American Off-Road Technologies, Llc Reduced-size vehicle with complementary internal compartments and suspension system components
US8191930B2 (en) 2004-12-30 2012-06-05 American Off-Road Technologies, Llc Frame design for reduced-size vehicle
US7617904B1 (en) * 2006-05-01 2009-11-17 Brp-Powertrain Gmbh & Co Kg Transmission for vehicle
US20110175398A1 (en) * 2008-07-24 2011-07-21 Alcoa Inc. Modular architecture for combat tactical vehicle
US7905540B2 (en) * 2008-07-24 2011-03-15 Alcoa Inc. Modular architecture for combat tactical vehicle
US20100019538A1 (en) * 2008-07-24 2010-01-28 Kiley Matthew P Modular Architecture for Combat Tactical Vehicle
US20110133518A1 (en) * 2009-12-03 2011-06-09 GM Global Technology Operations LLC Chassis structure of a motor vehicle body
US8714636B2 (en) * 2009-12-03 2014-05-06 GM Global Technology Operations LLC Chassis structure of a motor vehicle body
US20120104793A1 (en) * 2010-10-29 2012-05-03 Aptera Motors, Inc. Automotive vehicle composite body structure
US10259507B1 (en) * 2018-03-22 2019-04-16 Honda Motor Co., Ltd. Skid plate and underbody assembly for use with an off-road vehicle

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